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Aging Aircraft National Strategy Joint Council on Aging Aircraft 23 October 2003 Mr. Robert P. Ernst, USN JCAA Chairman 301-342-2203 [email protected] Agenda “The problem” JCAA Background National Strategy JCAA and Industry Scorecard Summary JCAA Membership

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aging aircraft national strategy

Aging Aircraft National Strategy

Joint Council on

Aging Aircraft

23 October 2003

Mr. Robert P. Ernst, USN

JCAA Chairman

301-342-2203

[email protected]

agenda
Agenda
  • “The problem”
  • JCAA Background
  • National Strategy
  • JCAA and Industry Scorecard
  • Summary
fleet wide aircraft age trend
Fleet-Wide Aircraft Age Trend*

*Data based on 2001 figures

Air Force

Navy

Commercial

Army

Differences in business operating rules readily apparent

agenda5
Agenda
  • “The problem”
  • JCAA Background
  • National Strategy
  • JCAA and Industry Scorecard
  • Summary
jcaa mission
JCAA Mission
  • Jointly Identify, Investigate, and Implement Programs that will Field Products to Improve the Availability and Affordability of all the Services’ and Agencies’ Aging Aeronautical Systems
slide7
Organizing for Action in JACG

USAF - Aging Aircraft

Program Manager

USA - Director for Transformation

USN - Aging Aircraft

Program Director

DLA - Aging Aircraft

Program Manager

FAA - Aging Aircraft

Director

USCG - Aging Aircraft

Branch Chief

USMC – HQMC

Dept of Aviation

NASA Langley

Structures&Materials

  • Joint Program Opportunities Board (JPOB)
  • Joint Aeronautical Armaments Board (JAAB)
  • Aviation Engineering Board (AEB)
  • Aviation Business Process Board (ABPB)
  • Aviation Logistics Board (ALB)
  • Science and Technology Board (S&T)
  • Joint Technical Coordinating Group on Aircraft
  • Survivability (JTCG/AS)
  • Joint Council on Aging Aircraft (JCAA)

JCAA: A JLC/JACG Chartered Board

aia ndia jcaa interface
AIA/NDIA/JCAA Interface

JCAA Expanded to Include Industry Representatives

Logistics Mgmt

Division

System Eng

Division

Product Support

Engineering Management

NDIA

AIA

Resources

IEEE

SAE

EIA

AIAA

AVSI

RITA

Other

Strategic

&

TacticalInitiatives

Two Way Flow of Ideas

jcaa approach
JCAA Approach
  • Through the use of Integrated Roadmaps, Shared Data and Analyses, the JCAA will:
    • Identify Process Recommendations & Improvements
    • Advocate/Enable Promising Technology
    • Facilitate Transition of Technology/Program Opportunities
    • Promote Knowledge Management on Aging Aircraft
    • Coordinate Funding for Promising Areas

Value Added: Integrated Roadmaps, Coordinated Funding, And Knowledge Sharing

Integrated Roadmaps, Coordinated Funding, and Knowledge Sharing

agenda10
Agenda
  • “The problem”
  • JCAA Background
  • National Strategy
  • JCAA and Industry Scorecard
  • Summary
why a national strategy
Why a “National Strategy”?
  • Resources are limited
    • USN FHP $2B/yr with 7.8% growth
    • 4:1 ROI requires $160M/yr investment
    • USN AA budget tops at $7M/yr
  • Solutions are fragmented
    • Many different approaches; many competing
    • Funding not “balanced”
      • Lack of transition and support $
  • Lack of Consensus between Govt/Ind
    • Are we incentivizing the right motives?

Work Smarter not Harder

national strategy what is it
National Strategy – What is it?
  • 12 Over arching Recommendations
      • Process
      • Critical Gaps
      • Not a “whine for funding”
  • Organized around 5 JCAA Steering Groups
    • Detailed Roadmap of funded efforts/gaps
  • Industry Interaction/Input Vital
  • Top 12 Issues Presented at Aging Aircraft Conference
  • Detailed Sections Available 11/30
  • Complete Report to industry 12/31
national strategy outline
National StrategyOutline
  • Chapter 1 –
  • Overview
  • Chapters 2-6
  • Detailed Discussion
  • Gaps/Issues
  • Chapter 7
  • Recommendations
national strategy focus
National Strategy Focus

Common Solutions to Aging Aircraft Issues

5 Process Issues

DLA

NDIA

Army

JCAA Focus

  • Maintenance Training
  • Analytical Methods/Cost of Aging
  • Corrosion Prevention
  • Transition of Commercial Products
  • Diagnostics/Health Monitoring Systems
  • Wiring Failure Detection
  • Arc Fault Circuit Interrupt Equipment
  • Structural Modeling and Analysis
  • Maintenance Manual Currency
  • Obsolescence Management
  • Avionics Modernization
  • Component Improvement

Navy

USMC

AirForce

FAA

Coast

Guard

AIA

7 Product Focus Areas

NASA

national strategy cost of aging
National Strategy - Cost of Aging

Actuals

Projections

What is Driving the costs?

What can we do to mitigate the increase?

air force trend summary 131 components studied
Air Force Trend Summary131 Components Studied
  • Primary Area for Air Force Cost Growth is Engine Component Related
  • No Helos or Prop Aircraft in AF DB Minimizes Dynamic Component Area
  • Age, New Items and Maintenance Plan Changes All Have Significant AF Impacts
  • Vendor Issues Do not Appear to be Significant Root Cause For AF
slide17
Corrosion Efforts - CPCs

Transitioning the Best Solutions

  • Roadmap “best of breed” Corrosion Solutions
  • Share qualification data/experience
  • USN FY-02/03 Project Savings:Over 257,000 MMHrs
  • 3. Attack “gaps” & Update common specifications

Industry – Better Material Selection Needed

structural health management
Structural Health Management

1+d

0.80

0.40

0.00

  • New Mission Requirements impose new loads spectra
  • Environmental effects increase with aging
  • Next generation methodology needed
    • Flexible
    • Damage tolerant

?

!

1.0 FLE

Average

FLE

Design/Test

0

2000

4000

6000

8000

Flight Hours

Requires:

Incorporation of WFD and crack growth methodology

Data sharing from teardowns/ load surveys

Industry Involvement Critical

avionics modernization
Avionics Modernization
  • Moving to characterize avionics /COTS performance
  • Predict (Manage) wear-out
  • Planned Systems Improvement
  • Changes in sparing?

MTBF

Time

AVSI Projects

16 Mitigating Radiation Effect on Semi Conductors

17 Accelerated Wear out of Semi Conductors

18 Thermal Management of COTS Based Avionics

Understanding the new generation of components

avionics modernization20
Avionics Modernization
  • Selecting the “right” option requires:
  • Understanding component/system life
  • Good analysis of options (ROI)
  • A Valid “tool box” of options
slide21
Current Obsolescence Efforts

Covers the Spectrum of Potential Solutions

Typical PMA >80% Redesign/ Replacement

Supply focus is on component

wiring initiative 2 of 4
Wiring Initiative 2 of 4

Wiring Diagnostic, Prognostic Equipment

  • Accomplishments:
    • Initiated Available Technology
      • USAF Wire Integrity Program
        • Re-evaluated hand held technology
        • Field Demonstration
      • Electronic Diagnosis and Characterization (ECAD) System Program – COSSI
        • Completed CDR
        • Organizational, Prognostic Evaluation
      • Automatic Wire Analyzer (AWA) Program NCMS CTMA (Contract Awarded) - Joint Navy, Air Force, Army Participation
    • Developed S&T Roadmap
    • Joint FAA BAA evaluation
  • Objective:Provide users with state of the art diagnostic and prognostic equipment

Common

hardware

specification

slide23
Roadmap For Wiring Training
  • Create Cross Functional Team
  • Wiring experts
  • Training experts
  • Fleet

5 Communities surveyed

210 individual responses

Aging Aircraft IPT

Manpower Personnel Training

Electrical Systems Division

Final Recommendations to NAVAIR and JCAA

Cost Analysis Department

overall training survey results
Overall Training Survey Results
  • Underutilization of:
    • CNET, CANTRAC and CBT (Training Assistance/ Tools for Feedback)
  • Unaware of:
    • NATEC (Technical Assistance)
    • New wiring malfunction codes
  • Training Needs:
    • Less time between training and actual work applying it
    • Time to practice training / Transfer of training
    • Refresher training
    • More in-depth training
    • More training on:
      • Wire Splicing Techniques
      • Proper Use of Crimping Tools
      • Selection of Wire and Connector Tools
      • Recognition and Repair of Connector Corrosion
agenda25
Agenda
  • “The problem”
  • JCAA Background
  • National Strategy
  • JCAA and Industry Scorecard
  • Summary
jcaa progress
JCAA Progress

Steering Groups

  • Established
  • Expanding
  • Resource Limited

Strategic Thrusts

  • Less progress
  • More groups involved

Funding

  • Limited
  • Complimentary

Consensus being Reached; Cultural Change Required

jcaa ndia interaction
JCAA/NDIA Interaction
  • Working Well
    • NDIA involvement in day to day business
    • Participation in weekly phone call
    • All JCAA meetings
  • On Track
    • National Strategy
      • Plan for discussion of “Strategy”
  • Needs Improvement
    • Industry Concerns
    • Organizing various Initiatives
    • OSD Support
aging aircraft conference

Aging Aircraft Conference

  • 2003 AA Conference
  • 950 attendees
  • JACG panel discussion
    • Structures
    • wiring
    • avionics
  • Unveiling of the
  • “National Strategy”

Next Conference 31 Jan 2005

Palm Springs CA

agenda29
Agenda
  • “The problem”
  • JCAA Background
  • National Strategy
  • JCAA and Industry Scorecard
  • Summary
where can industry help
Where can industry help?
  • Air Vehicle
    • Structural Health Management (crack growth…)
    • Corrosion Preventative Compound Development
    • CPC transition (legacy/new)
  • Avionics
    • Understanding of component life
    • Development (and use) of obsolescence “tool box”
    • Common parts selection/management processes
  • Wiring
    • Technology development/utilization
    • Best practices standardization
summary
Summary
  • JCAA is Active & Maturing
    • Limited by Service/Agency resources
    • FAA, NASA involvement increasing
    • Increasing consensus on issues
    • Collaboration on funding
  • Added Emphasis on Subsystems/Dynamic Components
  • Industry Participation Improves/Accelerates Progress
    • Excellent support from AIA
  • National Strategy will force discussion
    • Central Office Stand Up will facilitate
  • Strategic Progress Requires Extensive Collaboration

JCAA-Industry Collaboration is Crucial

obsolescence barriers
Obsolescence Barriers
  • Lack of Standardized Process
    • Consistent/Defendable Thresholds
  • Tools/handoff between process steps
  • Fragmented Funding
    • What Changes need to take Place?
  • Limited Metrics
    • Cost/Reliability/ROI
  • Standardized Qualification Criteria
  • What Data do we Buy?
    • Proposed Contract Language =

f( contract type)

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